Process Parameter Optimization Framework for the Selective Laser Melting of Hastelloy X Alloy Considering Defects and Solidification Crack Occurrence
Houichi Kitano, Masahiro Kusano, Masakazu Tsujii, Atsushi Yumoto, Makoto Watanabe
Abstract
Recent years have witnessed increasing demand for selective laser melting (SLM) in practical applications; however, determining the appropriate process parameter range remains challenging. In this study, a framework was developed to determine the appropriate process parameter range considering the occurrence of defects and cracks by conducting a single-track test and thermal elastoplastic analysis. Keyholing, balling, and the residual unmelted regions were considered defects. The occurrence of solidification cracking, which is predominant in the SLM of solution-strengthened Ni-based alloys, was considered. Using the proposed framework, we could fabricate a part with largely no defects or cracks, except for the edges, under the determined optimal process parameters.